Apparatus for the manufacture of insulated wire



Jan. 26, 1937. E. w. FoRsTRoM ET Ax.

2,069, APPARATUS FOR THE 'MANUFACTUR OF' INSULATED WIRE Filed Nov. 28, 1933 wn, @s if m SOHAUO FP O -m wwdfn @dw .a

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@at Ennuh IVI Mr n@ Patented lJan. 26it 1937 APPARATUS FOB. THE MANUFACTUBE F INSULATED WIRE Edward W. Forstrom and Cliiord 0. Hull, Stratford, Conn., assis-nots to General Electric Company, a corporation of New York Application November 2s, 1033, serial No. 700,105

8 Claims.

Our invention relates to the manufacture of insulated wire by a continuous process.

The object of our invention is to provide an improved method and apparatus for the manufacture of insulated wire.

Another object of our invention is to increase the speed of vulcanization of a rubber insulation and at the same time improve the product.

A still further object is to provide an entrance and exit seal for the vulcanizing chamber which will not injure the rubber covering on the core as it passes into and out of the vulcanizing chamber.

What we consider to be novel and our invention will be better understood by reference to the following specification and appended claims when considered in connection with the accompanying drawing.

In the drawing Figs. 1 (a) and 1 (b) are side elevations of the apparatus used in the manufacture of the rubber covered wire in which the right hand end of Fig. 1 (b) is a continuation of the apparatus from the left hand end of Fig. 1 (a): Fig. 2 is a sectional view on an enlarged scale of the entrance seal of the vulcanizing chamber, and Fig. 3 is a similar view of the exit seal.

In the manufacture of rubber covered wire by a continuous process considerable difficulty is experienced in the passage of the core after the rubber has been extruded on it into the vulcanizing chamber. One of the problems is to prevent injury to the rubber covering as it is easily damaged while it is still in the plastic state before vulcanization. Another problem is to prevent escape of the vulcanizing medium without at the same time damaging the plastic rubber covering. Similarly difficulties are experienced in the passage of the core from the exit end of the vulcanizing chamber. The main problem is due to moisture or excess air which may be entrained in the core before it is covered with rubber. No damage is done to the rubber covering while it is in the vulcanizing chamber due to the high pressure of the vulcanizing medium. However, when the core passes out of the vulcanizing chamber and the pressure is suddenly reduced the expanding gas bursts through the rubber covering. This produces Weak spots in the rubber which may result in a breakdown of the insulation in use or a condemning of a considerable length of the manufaotured product. These difficulties are magnined as the speed of the manufacture of the rubber covered wire is increased.

These and other diil'iculties are overcome by our improved method and apparatusfor the manufacture of rubber covered wire as will be explained in greater detail in the following description.

Referring to the drawing, I0 indicatesv a reel which carries a supply of the core I I which is to be provided with a covering of insulation. Core 5 II may consist of a bare Wire or a wire provided with a covering of insulating material over which it is desired to provide an additional rubber covering. Also, core II may consist of a plurality of separately insulated conductors combined with a filler over which it is desired to provide an overally rubber covering. For the purposes of this description core II will bereferred to as a wire. As Wire II passes from reel I0 it is looped over a tension regulator I2 which is pivoted at I3 and l5 provided with a spring bias I6. Upon a. sudden increase of the speed of wire II the loop about tension regulator I2 is shortened until reel I0 is speeded up to feed the wire I I at the desiredspeed. From tension regulator I2, wire II passes around an idler I5 through a wire straightener I6 into a preheat chamber I'I. In preheat chamber I 7, wire I I passes over=an idler I8 to a driven capstan I9. Idler I8 and capstan I9 are provided with a number of circular grooves and the Wire is passed from idler I8 to capstan I!!4 and back to idler I8. The wire II -may be passed about idler I8 and capstan I9 a number of times depending upon the amount of heating of Wire II which is desired. A source of heat 20 is provided and as shown con- 30 sists of a gas burner with a plurality of gas jets. Any'other source of heat may be used. Preheat chamber I'I serves to regulate the temperature of the Wire. Previously, diiiiculty was experienced in the covering of a wire with rubber and its subsequent vulcanization due to variation in temperature of the wire. To insure a relatively uniform temperature of the Wire it was necessary to store the wire for a period of days in a room held at a constant temperature. This difliculty 40 of course was greatly increased when the wire was being shipped in cold weather and so it was necessary to have a large stock of wire on hand in order to have some available which had been in the storage room for a considerable period of time. However, even though the reel of wire had been in the storage room for some time there was no certainty that the temperature of the Wire on the reel throughout its length was uniform. The problem of heating a reel of large diameter having a considerable length of Wire on it to insure a uniform temperature throughout the length of the wire is considerably greater than the heating of the wire as it passes through a chamber such as the preheat chamber I1. Also, the temperature of the wire passing from the preheat chamber I1 can be very closely regulated regardless of the temperature of the wire on reel I and can be made sulciently high to assist in the vulcanization of the rubber which speeds up the vulcanization of the rubber and assures complete vulcanization throughout the rubber covering. When a core which has been previously insulated is to be provided with a rubber compound covering it may or may not be necessary to pass it through the preheat chamber I1. From preheat chamber I1, wire II passes over a guide 2I around an idler 22 which is supported by an a 23 pivotally connected at 24 to a speed reg ator 25. Speed regulator 25 is located in the driving connection of capstan I9 and serves to regulate the speed of the capstan I9 automatically depending upon the speed of wire I I. Any variation in the speed of 'the wire causes a movement of idler 22 due to the shortening or lengthening of the loop about it. From idler 22, wire II passes about a guide 26 and through an extruder 21. As the wire I I passes through extruder 21 the rubber covering is provided. Ext'ruderY 21 is of a type well known to the artand it is believed unnecessary to describe its construction and operation. Extruder 21 is driven by a motor 23. Motor 28 is also connected to drive take-up capstan 29 directly and capstan I9 through speed regulator 25. Between the connection of motor 28 to capstan I 9 and take-up capstan 29 a transmission 30 is provided which includes gears for speed variation and a clutch. A pedal 3I is provided by which the clutchv may be disconnected to stop the feed of the wire I I through the extruder 21. From extruder 21, wire II passes to the entrance seal 32 of the vulcanizing chamber 33. Seal 32 is provided and adapted to prevent damage to the rubber compound coveringwhile the rubber compound is in the plastic state as it passes into the vulcanizing chamber 33. Seal 32 also prevents the escape of the vulcanizing medium which is maintained at a relatively high pressure in the vulcanizing chamber 33. Seal 32 will be better understood by reference to Fig. 2 in which it is shown on an enlarged scale in section. Seal 32 consists of a tube 34 in which are located a number of identical glands 35 which have a central opening sumciently large to permit the easy passage of wire I I with its rubber covering, and also have an enlarged concentric opening 36 at one end. The number of glands 35 provided depends upon the length of tube 34 which, in turn, is governed by the pressure of the vulcanizing medium as will be explained later. At opposite ends of tube 34, glands 31 are provided with central openings of the same diameter as the openings of glands 35. Glands 31 diier from glands 35 in that their central portion is longer and no enlarged opening is provided. At the entrance end of tube 34 between gland 31 and the adjacent gland 35 a spacer 39 is provided having openings 40 communicating with a nipple 4I secured in an opening in the bottom of ltube 34. Tube 34 is threaded into a gland 42 which is secured in a ange 43 by a nut 44. Glands 35 and 31 and spacer 39 are secured in tube 34 by engagement at lone end with a shoulder on gland 42 and by a clamping nut 45 on the entrance end of the tube 34. Flange 43 is connected to the vulcanizing chamber 33v and has an opening communicating therewith. Gland 42 has a screw threaded plug 46 at one end with a central opening for the passage of wire II with its rubber covering into the vulcanizing chamber 33. Gland 42 is also provided with radial openings communicating with a pipev 41 which is screwthreaded in an opening in the bottom of ange 43.

Pipe 41 is connected to a iiuid supply which may be water, air', or other suitable uid at a pressure slightly in excess of the pressure of the vulcanizing medium in the vulcanizing chamber 33. This prevents the escape of "the vulcanizing medium through the entrance' seal 32fand a small amount of the water entering pipe 41 passes through nut 46 into the vulcanizing chamber. The greater portionof thei water, however, passes through glands 35 and out of nipple 4I. The pressure of the water is reduced as it passes through glands 35 sufficiently so that` while a small amount may pass out through the entrance end of tube 34 the amount is limited by the reduction of the water pressure. Thus tube 34 must be sufiiciently long so that the pressure of the water entering pipe 41 will be reduced'to approximately atmospheric pressure near the entrance endv of the tube. The water passes through the small central openings of glands 35 and due to the small clearance between these openings and the wire II with its rubber compound covering and also due to the high water pressure necessary to prevent the escape of the vulcanizing medium the water may attain a considerable velocity.' The enlarged openings 36 provided in glands 35 serve to prevent an excessive velocity of the water being attained which would result in a turbulent flow and would damage the rubber covering by making the surface of the rubber covering uneven or even possibly stripping the rubber covering from the wire II and stopping up the central opening of glands 35. The velocity of the water flowing through the central openings of glands 35 vis limited by the resistance to the continuous flow of the water by the enlarged openings 36. The eddy currents set up in the enlarged openings 36 reduce the pressure head at the entrance to the central opening of each gland 35. 'I'he arrangement of these enlarged openings is important as the rubber covering, prior to vulcanization, while it is still in its plastic state is very easily damaged and any unevenness in its surface would result in a weakening of its insulation as the thickness of insulation would be reduced at certain points. The pressure of water entering pipe 41 may only be a fraction of a pound in excess of the pressure .of the vulcanizing medium as that is suflcient to prevent the escape of the vulcanizing medium.

Wire I I passes from seal 32 linto the vulcanizing chamber 33 which consists of a pipe into which is supplied a vulcanizing medium, such' as steam, at one point or a plurality of points, one such supply being indicated at 48 in Fig. 1 (a). The pressure of the vulcanizing medium is determined by the length of the vulcanizing chamber 33 and by the speed at which it is desired to pass the wire with its rubber covering through the vulcanizing chamber. Vulcanizing chamber 33 is covered by a heat resisting insulation 49 to prevent excessive heat radiation due to the high temperature of the vulcanizing medium. To carry away any condensate and any water entering the vulcanizing chamber through entrance seal 32, drain pipes 50 and I are provided and connected to a steam trap which is not shown on the drawing. Similarly at the exit end of the vulcanizing chamber drain pipes 52 and 53 are provided and connected to a steam trap. To prevent escape of the vulcanizing medium as the wire I I passes out of the vulcanizing chamber and also to prevent damage to the rubber lcovering of the wire as it leaves the vulcanizing chamber an exit seal 54 is provided which is shown on an enlarged scale in section in Fig. 3. Exit seal 54 is similar to entrance seal 32. A tube 55 is provided in which a' number of glands 56 are located which have central openings through which the wire I I with its vulcanized rubber covering passes with a small clearance. Between the gland 56 at thev exit end of tube 55 and the next adjacent gland 56 is provided a spacer 58 which has openings 59 communicating with a nipple 6l) secured in an opening in the bottom of tube 55. Tube 55 is in screw threaded engagement with a gland 6I located in flange 62 which is secured to the vulcanizing chamber 33. Gland 6I is secured in flange 62 by means of a nut 63. Glands 56 and spacer 58 are clamped in position in tube 55 by engagement with a shoulder on gland 6I at one end and by a clamping nut 64 threaded on the exit end of tube 55. Water is supplied to flange 6I by a pipe 65 and enters through openings provided in gland 6I into the central openings of glands 56. A plug 66 with a central opening is threaded into gland 6I in an opening provided in gland 62 communicating with the vulcanizing chamber. The water entering through pipe 65 is maintained at a pressure slightly in excess oi the vulcanizing medium in the vulcanizing chamber 33 and this prevents the escape of the vulcanizing medium with wire II a small portion of the Water passing through plug 66 into the vulcanizing chamber. The remainder of the water passes through central openings in glands 56 in the clearance between the wire iI with its vulcanized rubber covering. Due to the fact that the rubber covering of wire II is vulcanized as it enters into the exit seal 55 it is unnecessary to provide enlarged openings in the glands 56 to reduce the velocity and turbulence of the water as in the case of entrance seal 32. The tube 55 is of sumcient length to cause a reduction in the water pressure as it travels from the end of tube 55 connected to gland 6| toward the exit end sufciently so that it is approximately at atmospheric pressure and very little of the Water escapes through the exit end of seal 55 with the wire II, but instead is drained out through nipple 68. The gradual reduction in pressure of the water as it passes throughtube 55 is of importance in addition to the fact that it prevents a large amount of the water escaping with the wire as it gradually reduces the pressure surrounding the covering of wire II as it moves from the vulcanizing chamber so that any air or moisture entrained in the core in case the wire Il has previously been insulated before the rubber covering is applied, Will not be suddenly released from a high pressure which might result vin the rapid expansion of the entrained air or moisture bursting through the rubber covering and producing defects in the rubber covering. Simultaneously with the gradual reduction in pressure as Wire II passes through tube 55 the covering of wire II becomes chilled due to the relatively low temperature of the water entering pipe 65, the largest portion of which subsequently oWs through the central openings of glands S contacting the covering of wire II as it passes through tube 55. It is obvious, therefore, that the covering of wire I I is suddenly reduced in temperature as it passes through tube 55 while subjected to the gradual reduction in pressure thus contracting the gases due to the entrained air or moisture under the rubber covering and consequently assisting to eliminatev the explosion of the gases as the wire II leaves the exit seal. 'I'hese latter advantages of the gradual reduction in the water pressure and, reduction of temperature of the i'sulated wire in the exit seal 55 is important in the use of a continuous process for the vulcanization of overall rubber coverings on previously insulated conductors especially when a plurality of conductors are cabled together. It is practically impossible to completely remove all the entrained air and moisture from the fibrous ller and so some means is necessary to prevent escape of the entrained air and moisture through the rubber covering after its vulcanization and as it leaves the vulcanizing chamber. Wire I I passes from the exit seal 55into a chamber 61 about an idler 68. Chamber 61 is provided to drain the Water which passes out through the exit end of seal 55 and may be carried by wire II. Wire II then passes over a guide 69 and into a cooling tube 1D. Cooling tube 10 is of relatively small diameter and is supplied with cold water at a low pressure through pipe 1I. As the wire I I passes from one vend of tube to the other at a relatively high velocity it carries with it the water fed at a low pressure, which water practically lls tube 10 and serves to cool the vulcanized rubber covering which is completely immersed in the water. The cooling of the rubber covering on wire I I is desirable to prevent superaging of the rubber covering after it leaves the vulcanizing chamber due to the high temperature which it attains in its passage through the vulcanizing chamber 33. To

remove the moisture from the rubber covering of wire II as it passes out of cooling tube 10 an air wiper 12 is provided into which air at a suitable pressure is fed through tube 13. The air wiper is not shown in detail but consists of a cylindrical nozzle which surrounds the wire by which air is directed in the opposite direction to that in which the wire is moving and causes the water to drain oi through tube 1d back to cooling chamber 61. Wire II then passes through a chamber in which soapstone is applied to the rubber covering to prevent the adjacent turns of the rubber covered wire on the take-up reel sticking together. The soapstone is applied in chamber 15 to the wire in liquid form so that a very thin coating is provided. The chamber 15 is connected by pipe 16 to pipe 13 which supplies the air to dry the rubber covering after the application of the soapstone. Wire II then passes between two vertical guide rolls 11 and over three idlers 18. cured to the same support is a disc 19 which is in engagement with wire II just above center idler 18. Disc 19 is rotated by the movement of wire II and is connected to a mechanism not shown which records the number of feet of rubber covered wire manufactured. The weight of disc 19 and the recording mechanism connected to it is counter-balanced by a weight 80. Wire II next passes under a guide 8| to a grooved roll 32 above which is pivotally mounted a small disc 83 which engages the top of wire I I as it passes over grooved roll 82. Connected to the arm on which small disc 83 is pivoted is a micrometer 84 which may give a direct reading of the diameter or may indicate variations in the diameter of the rubber covered wire. Wire II then passes over an idler 85 to take-up capstan 29. The wire passes cornpletely around take-up capstan 29 to an idler 86 and then back over take-up capstan 29. From take-up capstan 29 the wire then passes between two rollers 81 and 882 Roller 81 is driven by a motor 89. Roller 88 is pivoted and counter-balanced by a weight 98 to hold wire II in engagement with roller 81. By this arrangement wire II is supported and positively driven between the Pivotally sevtake-up capstan 29 and the take-up reels. Wire I I then passes over a guide pulley 9| which directs the wire to traverse 92. Guide 9| is connected to a piston in air cylinderA 93. Air is supplied to air cylinder 93 through a pipe 94 or pipe 95 when it is desired to move guide 9| from one position to another. In the "position indicated in the drawing, guide 9| directs wire to guide 96 on the right of traverse 92. When in this position the wire is directed to a. take-up reel 91 on which the vulcanized M rubber covered wire is being wound. Take-up reel 91 is driven by a motor 90. Motor 98 also drives travese 92 through the intermediary of chain 99. When a suicient length of wire has been wound on take-up reel 91 air is admitted to air cylinder 93 through pipe 94 and guide pulley 9| is'shifted from the position indicated in the drawing to the left to a position which directs the wire to guide |00 on the left of traverse 92. The wire is then wound on take-up reel |0| and traverse 92 serves to distribute the wire evenly on the surface of the reel. Take-up re'el |0| is driven by a motor |02 which is also connected by a chain |03 to drive traverse 92. The two reels 91 and |0| are driven at the same speed when the wire is shifted from the one to the other. After the wire is shifted it is severed between the reels by a cutter not shown. The motor driving the full reel may then lbe disconnected and the full reel replaced by an empty one. It is to be noted that while the preheat chamber |1 is shown as located adjacent to the extruder 21, it may be desirable to space the preheat chamber further from the extruder 21 in order to permit the application of an insulating cover of fibrous or other material about the wire prior to the passage `oi the Wire into the extruder. In a like manner, it might be desirable to space the extruder 21 further from th entrance seal 32 to permit the application of a covering subsequent to the extruding of the rubber over the wire and prior to its entrance into the vulcanizing chamber. It may also be desirable to apply a protec` tive covering of brous or other materials over the vulcanized rubber insulation at some convenient place along the return travel of wire between the exit seal and the take-up equipment. Bythe arrangement of this apparatus the wire is first h eated to a desired temperature to obtain a uniform( temperature of the wire throughout its length and to cause the rubber covering when subsequently applied to adhere closely tothe wire and to assist in the vulcanization of the rubber. The rubber covered wire is then passed into the vulcanizing chamber through a seal which prevents the escape of the vulcanizing medium and at the same time protects the rubber covering from damage as it enters the vulcanizing chamber. The rubber covering is vulcanized in its passage through the vulcanizing chamber. 'Ihe speed at which the wire may be passed through the vulcanizing chamber depends upon the length of the vulcanizing chamber, the temperature of l the vulcanizing medium, and the thickness of the rubber covering. The rubber covered wire is then passed out from the vulcanizing chamber through a seal which protects the vulcanized rubber covering and also prevents the escape of vulcanizing medium from the exit end of the vulcanizing chamber.l The rubber covering is then cooled to prevent superaging of the rubber and to provide uniform cooling of the insulation. The wirewith its vulcanized rubber covering is finally Wound on a take-up reel. The method and combination of the apparatus which successively operates` on the wire facilitates the speed with which the rubber covered wire can be manufactured and improves the product which may be produced. Obviously the invention is not limited to the provision of a.

rubber covering but may be used for the application of any plastic insulating material which requires vulcanization or heat treatment.

What we claim as new and desire to secure by Letters Patent of the United States is:

1. In an apparatus for applying a covering of insulating material to a core, means for applying insulating material to the core, a vulcanizing chamber, means for supplying a vulcanizlng medium at a high pressure to the vulcanlzingchamber, a seal for the vulcanizing chamber, means for supplying a uid to said seal at a pressure in excess of the pressure in the vulcanizing medium 'in the vulcanizing chamber to prevent the escape of vulcanizing medium.

2. In an apparatus for applying a covering of insulating material to a core, means for applying the insulating material to the core, a vulcanizing chamber, means for supplying a vulcanizing medium to the chamber at a high pressure, a seal for the entrance end of the vulcanizing chamber through which the wire is adapted to pass into the vulcanizing chamber, means for supplying water to the entrance seal at a pressure above the pressure of the vulcanizing medium to prevent escape of the vulcanizing medium as the core entersthe chamber, a second seal for the exit end of the vulcanizing chamberY through which the core passes on leaving the chamber, and means for supplying water to said second seal at a pressure above the pressure of the vulcanizing medium to prevent escape of the vulcanizing medium as the core leaves thechamber.

3. In an apparatus for applying insulating material to a core, means for applying the insulating material to. the core, a vulcanizing chamber, means for supplying vulcanizing medium to the chamber, a seal for the vulcanizing chamber comprising a tube, a plurality of glands secured in the tube having central openings for the passage of the core and enlarged openings, means for supplying water to the seal adjacent its connection to the vulcanizing chamber at la pressure above the'pressure of the vulcanizing medium whereby the escape of the vulcanizing medium is prevented and damaged to the insulating material covering the core by the high pressure water is prevented by the enlarged openings of the glands which reduce the velocity of the water.

4. An apparatus for manufacturing rubber covered wire, means for applying a rubber covering to the wire, a vulcanizing chamber, means for supplying a vulcanizing medium to the chamber, a seal for the vulcanizing chamber, means for supplying a iluid to the seal at a pressure above the pressure of the vulcanizing medium, glands located in the seal having central openings for the passage of the wire and enlarged openings to reduce the velocity of the fluid passing through the seal to prevent damage to the rubber covering on the wire.

5. An apparatus for manufacturing rubber covered wire, means for applying the rubber covering to the wire, a vulcanizing chamber, means for supplying a vulcanizing mediuml to the chamber, a seal foreach end ofptlgeggulfenzng chamber, means for supplying water to the seal at a pressure above the pressure of the vulcanizing medium in the chamber, and glands for the seal at the entrance end of the vulcanizing chamber having central openings for the passage of the wire and rubber covering, and enlarged openings to reduce the velocity of the water owing through the seal to prevent damage to the rubber covering.

6. In an apparatus for manufacturing'rubber covered wire, a heating chamber, means for controlling the'temperature of the Wire as it passes through the heating chamber, means for applying a covering to the Wire after it leaves the heating chamber, a vulcanizing chamber, means for supplying a vulcanizing medium to the chamber, an entrance seal for the vulcanizing chamber through which the wire and rubber covering pass into the vulcanizing chamber, means for supplying water to the entrance seal at a pressure above the pressure of the vulcanizing medium to prevent escape of the vulcanizing medium, an exit seal for the vulcanizing chamber through which the wire and rubber covering are adapted to pass as they leave the vulcanizing chamber, and means for supplying Water to the exit seal at a pressure above the pressure of the vulcanizing medium to prevent escape of the vulcanizing medium.

"7. An apparatus for manufacturing rubber covered wire, a heating chamber, means for controlling the temperature ofthe Wire as it passes through the heating chamber, means for applying the rubber cover to the Wire after it leaves the heating chamber, a Vulcanizing chamber,

-means for supplying a vulcanizing medium to the vulcanizing chamber, a seal for the entrance end of the chamber, means for supplying Water to a seal at a pressure above the pressure of the vulcanlzing medium to prevent escape of the vulcanizing medium, a seal" for the vulcanizing chamber through which the wire is adapted to pass as it leaves the vulcanizing chamber, means for supplying water to the seal at a pressure above the pressure of the vulcanizing medium, a cooling tube through which Wire is adapted to pass after 5 it leaves the vulcanizing chamber, and means for supplying water at a low pressure to the cooling tube.

8. In an apparatus for manufacturing rubber covered wire, a heating chamber, means for controlling the temperature of the wire as it passes through the heating chamber, means for applying a rubber covering to the Wire afterit leaves the heating chamber, a vulcanizing chamber, means for supplying vulcanizing medium to the vulcanizing chamber, a seal for the vulcanizing chamber through which the Wire is adapted to pass as it enters the vulcanizing chamber, means for supplying water to the seal at a pressure above the pressure of the vulcanizig medium to pre-f vent the escape of the vulcanizing medium, a second seal for the vulcanizing chamber through which the wire is adapted to pass as it leaves the vulcanlzlng chamber, means for supplying water to said second seal at a pressure above fthe pressure of the vulcanizing medium to prevent 'escape of the vulcanizing medium, a cooling tube through which the wire is adapted to pass after it leaves the vulcanizing chamber, means for supplying Water to the tube, and an air wiper to remove moisture from the Wire as it leaves the cooling tube.

EDWARD W. FORSTROM.

CLIFFORD O. HULL. 

